Engineering a Supervisory Control System for Industrial IoT Operations

SequoiaAT helped an industrial client modernize supervisory control with a modular decision engine, real time alarms, and edge aware logging. The result is a reliable platform that scales with new devices and logic.

Client

Confidential industrial manufacturer

Leader in industrial automation with complex equipment lines and strict uptime goals.

Domains
  • Industrial Automation
  • Embedded Systems
  • IoT and Edge

Business Need

Process continuous telemetry from pressure and temperature sensors and generator equipment.

Respond to environmental and operational changes through configurable control logic.

Provide real time alarm visibility with operator acknowledgment.

Support modular expansion through a microservice based architecture and backend integration.

Improve traceability with durable event logging and historical analysis for audits and diagnostics.

Increase resiliency with edge level persistence under intermittent connectivity.

SequoiaAT Engineering Approach

System audit and architecture design

Comprehensive review of data ingestion paths and time series storage. Modularized existing code for maintainability and scale.

Supervisory control service

Central decision engine based on a configurable state machine. Evaluates thresholds, timers, and combined equipment states to trigger actions and alerts.

UI and backend integration

Web dashboard for active alarms prioritized by severity with acknowledgment flows. Backend services log structured events into time series storage and support simulation based testing.

System Architecture Summary

Edge Compute Layer

Collects data from sensors and devices with local persistence for resiliency.

Messaging Framework

Low latency links connect devices to the supervisory engine.

Supervisory Engine

State aware evaluation of readings and device states to drive control actions.

Alarm and Logging

Real time alarms with operator in the loop and structured event logging.

Frontend Dashboard

Live status and alarm management with role based access.

Telemetry Storage

Time series storage for analysis and compliance.

Impact

Automation of control logic

Reduces manual intervention with intelligent rule based decisions.

Real time awareness

Delivers live insights and actionable alarms to operators.

Operational traceability

Persists system states and actions for diagnostics and audits.

Modular expansion

Microservice design supports future devices and logic without rework.

Digital transformation

Bridges physical devices with cloud and application layers.

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